Variable coupled inductor

Patent metadata

Field	Value
Publication number	US-11017937-B2
Application number	US-201815972238-A
Country	US
Kind code	B2
Filing date	May 7, 2018
Priority date	Aug 21, 2012
Publication date	May 25, 2021
Grant date	May 25, 2021

Abstract

A variable coupled inductor comprises a first core having a first protrusion, a second protrusion, a third protrusion, a first conducting-wire groove and a second conducting-wire groove on the top surface of the first core, wherein the second protrusion is disposed between the first protrusion and the third protrusion, wherein a first conducting wire is disposed in the first conducting-wire groove, and a second conducting wire is disposed in the second conducting-wire groove, wherein a second core, disposed over the first core, wherein a magnetic structure is integrally formed with the second core and protruded on the bottom surface of the second core, wherein the bottom surface of the magnetic structure is located over the top surface of the second protrusion.

First claim

What is claimed is:

1. A variable coupled inductor, comprising:
a first core having a top surface and a bottom surface, a first lateral surface and a second lateral surface opposite to the first lateral surface, wherein the first core comprises a first protrusion, a second protrusion, a third protrusion, a first conducting-wire groove and a second conducting-wire groove, each of which extending from the first lateral surface to the second lateral surface on the top surface, wherein the second protrusion is disposed between the first protrusion and the third protrusion, wherein a first conducting wire is disposed in the first conducting-wire groove with a portion of the first conducting wire extending from the first lateral surface to the second lateral surface, and a second conducting wire is disposed in the second conducting-wire groove with a portion of the second conducting wire extending from the first lateral surface to the second lateral surface; and
a second core, disposed over the first core, wherein a magnetic structure is integrally formed with the second core and protruded on a bottom surface of the second core, wherein a bottom surface of the magnetic structure is located over a top surface of the second protrusion, wherein the top surface of the second protrusion is respectively lower than a top surface of the first protrusion and a top surface of the third protrusion, and the top surface of the second protrusion is respectively higher than a bottom surface of the first conducting-wire groove and a bottom surface of the second conducting-wire groove, wherein the bottom surface of the magnetic structure is disposed on and in contact with the top surface of the second protrusion and a total area of the bottom surface of the magnetic structure is smaller than a total area of the top surface of the second protrusion with side surfaces of the second protrusion being not used for winding a conductive wire therearound.

2. The variable coupled inductor according to claim 1 , wherein a first gap is formed between the top surface of the first protrusion and the bottom surface of the second core, a second gap is formed between the top surface of the second protrusion and the bottom surface of the second core and a third gap is formed between the top surface of the third protrusion and the bottom surface of the second core, wherein a vertical distance of each of the first gap and the third gap is respectively smaller than a vertical distance of the second gap, wherein the variable coupled inductor has a height H, and the vertical distance of each of the first gap and the third gap is between 0.0073H and 0.0492H, and the vertical distance of the second gap is between 0.0196H and 0.1720H.

3. The variable coupled inductor according to claim 2 , wherein the magnetic structure has a first magnetic permeability μ 1 , each of the first gap and the third gap has a second magnetic permeability μ 2 , and the second gap has a third magnetic permeability μ 3 , wherein a relationship between the first magnetic permeability μ 1 , the second magnetic permeability μ 2 and the third magnetic permeability μ 3 is: μ 1 >μ 2 ≥μ 3 .

4. The variable coupled inductor according to claim 2 , wherein the first core has a fourth magnetic permeability μ 4 , and the second core has a fifth magnetic permeability μ 5 , wherein a relationship between the first magnetic permeability μ 1 , the second magnetic permeability μ 2 , the third magnetic permeability μ 3 , the fourth magnetic permeability μ 4 and the fifth magnetic permeability μ 5 is: μ 1 ≥μ 4 >μ 2 ≥μ 3 and μ 1 ≥μ 5 >μ 2 ≥μ 3 .

5. The variable coupled inductor according to claim 1 , wherein a first gap is formed between the top surface of the first protrusion and the bottom surface of the second core, wherein the first gap is filled with a non-magnetic material.

6. The variable coupled inductor according to claim 5 , wherein a third gap is formed between the top surface of the third protrusion and the bottom surface of the second core, wherein the third gap is filled with a non-magnetic material.

7. A variable coupled inductor, comprising:
a first core having a top surface and a bottom surface, a first lateral surface and a second lateral surface opposite to the first lateral surface, wherein the first core comprises a first protrusion, a second protrusion, a third protrusion, a first conducting-wire groove and a second conducting-wire groove, each of which extending from the first lateral surface to the second lateral surface on the top surface, wherein the second protrusion is disposed between the first protrusion and the third protrusion, wherein a first conducting wire disposed in the first conducting-wire groove with a portion of the first conducting wire extending from the first lateral surface to the second lateral surface, and a second conducting wire disposed in the second conducting-wire groove with a portion of the second conducting wire extending from the first lateral surface to the second lateral surface; and
a second core, disposed over the first core, wherein a magnetic structure is integrally formed with the second core and protruded on a bottom surface of the second core, wherein a bottom surface of the magnetic structure is located over a top surface of the second protrusion, wherein the top surface of the second protrusion is respectively lower than a top surface of the first protrusion and a top surface of the third protrusion, and the top surface of the second protrusion is respectively higher than a bottom surface of the first conducting-wire groove and a bottom surface of the second conducting-wire groove, wherein a total area of the bottom surface of the magnetic structure is A 1 , and a total area of the top surface of the second protrusion is A 2 , wherein A 1 /A 2 is configured in a pre-determined value based on a pre-determined current value at a conversion point between light load and heavy load situations of the variable coupled inductor, wherein the bottom surface of the magnetic structure is disposed on and in contact with the top surface of the second protrusion and the total area of the bottom surface of the magnetic structure is smaller than the total area of the top surface of the second protrusion with side surfaces of the second protrusion being not used for winding a conductive wire therearound.

8. The variable coupled inductor according to claim 7 , wherein a first gap is formed between the top surface of the first protrusion and the bottom surface of the second core, a second gap is formed between the top surface of the second protrusion and the bottom surface of the second core and a third gap is formed between the top surface of the third protrusion and the bottom surface of the second core, wherein a vertical distance of each of the first gap and the third gap is respectively smaller than a vertical distance of the second gap, wherein the variable coupled inductor has a height H, and the vertical distance of each of the first gap and the third gap is between 0.0073H and 0.0492H, and the vertical distance of the second gap is between 0.0196H and 0.1720H.

9. The variable coupled inductor according to claim 8 , wherein the magnetic structure has a first magnetic permeability μ 1 , each of the first gap and the third gap has a second magnetic permeability μ 2 , and the second gap has a third magnetic permeability μ 3 , wherein a relationship between the first magnetic permeability μ 1 , the second magnetic permeability μ 2 and the third magnetic permeability μ 3 is: μ 1 >μ 2 ≥μ 3 .

10. The variable coupled inductor according to claim 8 , wherein the first core has a fourth magnetic permeability μ 4 , and the second core has a fifth magnetic permeability μ 5 , wherei

Assignees

• Cyntec Co Ltd

Inventors

• Hsieh Lan-Chin
• Lee Cheng-Chang
• Chang Chih-Hung
• Chuang Chih-Siang
• Wu Tsung-Chan
• Hsieh Roger

Classifications

• H01F3/14 Primary

  Constrictions; Gaps, e.g. air-gaps (in magnetic shunt paths H01F3/12) · CPC title

• H01F38/023

  of inductances · CPC title

• H01F27/2823

  Wires (H01F27/2866 takes precedence) · CPC title

• H01F27/24 Primary

  Magnetic cores · CPC title

• H01F2003/106

  Magnetic circuits using combinations of different magnetic materials · CPC title